Mattress and the like



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MATTRESS AND THE LIKE Filed Mach 27, 1940, Sheets-Sheet l wlTNEssES:

2 Shets-Sheet 2 INVENToR M1/f' @Q2/vs.

l 02. a@ ATTORNEYA w. DE FRn-:s

MATTRESS AND THEv LIKE Filed March 27, i940 March 23, 1943.

WITNESSES: @a 7' l Patented Mar. 23, 1943 Walter de Fries, Pittsburgh, Pa., assignor to Fort Pitt `Bedding Company, a corporation of Penn- Sylvania Application `lrMarch A2'7, 1940, #Serial .3No. 326,202l

v3-C`lullis. (Cl. v218-379) This invention relates Ito the Vmanufacture o-f mattresses and other upholstered articles yand particularly the "preferred type Yof `such articles having a Asmooth lexterior nish.

This application isa continuation-irrepart Vof my copending application 'Serial 'No. 213,576, filed June 14, 1938.

It is customary to use various types of 'pads and 'filling in the 'manufacture of vthis merchandise, usually 'assembled with 'individual `steel 'springs or prebuilt vspring units, the padding 'and lling being spread over the surface formed lby the spring assembly 'and being secured thereto by some manner o'f stitching'or'tufting'eitherinside 'of `the outer cover or even through the latter, `to prevent shifting 'and dislocation of the different paddings orupholsterymaterials from their desired `positions 4relative to each other. Such assemblyxmethods 'usually 'leave some -lines 'or points'of indentations, such as tufts, the eliminationof lwhich is desirable in the interest of better appearance and easier cleaning, particularly on merchandise styled in the modern manner 'featuring designs 'of relativelylarge 'unbroken areas.

One 'object 'ofth'e present invention, therefore, is to eliminate the familiar tuftin'gpr'actice 'and replace it with other means vfor prevention of relative 'shifting vof the 'paddings Felt prepared 'from "staple cotton Aor cotton linters'is one of the most common types of p'ad- `ding utilized in goods 'of th'e nature referred to. Where used in connection with cushion spring assemblies, it is `normallyunder'laid with .a sheet of woven material, suchas vburlap and jute or a pad prepared from longer vegetable fibers, such as sisal and th'e like, which bridges the open ysurface area of the spring assembly and'thus prevents the felt from Working down 'into them.

No methods other 'than sewing, stitching, or tufting'have been vfound"commercially successful prior to my present `invention "for .securing Athe majority ofrdomestic cotton felts "to a backing of Woven Vsheeting or carded unspun fibers. Attempts to punch'orneedle the comparatively short fibers ofsu'ch `cotton felt batting in 'its usual 'thickness to an underlying fabric or fiber base have failed to yield useful results. VOther efforts 'to secure a `vbond between two such 'layers by means ,of an adhesive, 'such as, for instance, sili- 'cate of soda or latex, have "proved toocostly, as the open or rough surface of Veach of the materials did'not lend litself to an economic or effective application of'any adhesive compound.

Searching Vfor ,an .explanation o f the known difiiculties of eiecting such bond by y.needling or punching the shorter cotton or'linter fibers into the carded base of longer fibers, iI found that the majority 'of domestic staple cotton or linter clings -to its adjacent 'fibers with more tenacity than `to `the^punching needle, 'so that the latter l'cannot punch a number of these fibers from a felt -batt ofv average thickness into `the underlying base. Byreducingthe thickness of such batts, more favorable results were obtained'particularly 4after the cotton felt was prepared from a cotton characterized `by vth'e harshness of its ber. Such material may comprise certain imported staple cottons or vbleached domestic lint'ers, for example. Again the surface characteristics of the .base ber are of importance as causing the cotton ber adheringto the needle to strip readily therefrom and to cling to the base fiber. I find that c'oir (cocoanut husk) fiber, with its rougher surface, `is vpreferable for my purpose, although sisal, manila, palm or other long bers may be employed in achieving "certain of the advantages of'my present invention. l

Thus, by covering a carded coir fiber base pad, 'inherently having relatively long, harsh, unspun fibers, with a rather thin layer v(or -series of layers) of Vharsh staple cotton felt (the fibers being less harsh than those of the vcoir base), I have been able to produce a mechanical bond between these Ytwo materials by means of needling or punching.

If only one .thin layer of harsh staple cotton 'felt is "applied, the described combination, by itself, is 'not suited las a ll'er for upholstered merchandise "for the reason that the structural firmness of the vWeb-like cotton felt topping has inadequate body to hold .together properlyand needs reinforcing to 'meet satisfactory service requirements. I therefore press additional layers of standard staple cotton or linter Yfelt into 'thebase layer, again securing a satisfactory bond by the well-knownknitting action offelted-cotton fibers with each other. Should this accumulation of felted cotton pads ontop of each other producea lufiiness of a degree which would 'cause permanent compression under repeated load or use-known in the trade as a body impression and vappearing eventually on most all mattresses Vwhich are lled with blown or felted 'staple cotton, or cotton `linter exclusively-I prejfer to punch one or more additional layers of harsh cotton felt onto'the base layer, building up by such action a punched felt foundation. which has adequateY compressive strength to yield under normal loadswithout taking a permanent set. The number and thickness of, the top felt pads pressed onto lthis foundation may then be reduced 'to no more than required to smooth out the punching indentations and thus obtain the vdesiredsmooth surface. Thus, cotton felt padding of anyrcomposition and in anyrdesired thickness may be joined to a carded long iiber base by the use of an intermediatelayer or layers ofrpreferably harsh cotton felt, needled to the base.

Whereas under present` economic conditions in 'the world cotton markets, a greater length of such harsh fibers with respect to the felt batt fibers may prevail, such a condition is not essential to my present invention. The essential difference is that the thin intermediate layer of cotton must have harsh and stii fibers, which adhere to the punching needle on its down stroke, yet strip readily therefrom on the pull-out stroke of the needle.

A further object of my invention is, therefore, to provide an upholstery material suitable for use as a spring insulator as well as a resilient padding, comprising a base layer of relatively long and firm garnetted fibers and a top layer of relatively short and soft fibers likewise garnetted or felted, with a resultant surface which Will not knit with or adhere to that of the base layer, and to join these two through the medium of an intermediate layer composed of garnetted or felted fibers, whose harshness permits some of their strands to be punched into the base layer, so as to form a mechanical connection therewith, and whose free surface offers, through the interlacing action of its fibers, adequate adhesion for the top layer to prevent its sliding or shifting relative to the lower layers.

As an added feature of my invention, I have found that the bonding or knitting action between the top and intermediate layer of thecotton felt may be increased by forming one or both of the contacting surfaces with frequent indentations placed at random or in keeping with a certain pattern, as, for instance, the familiar waffle design. Such unevenness of one surface requires the contacting material to conform thereto, when it is pressed on and thereby aids further in preventing any shifting or sliding action along the line of cleavage between any two sections.

A further object of my invention is to provide upholstery material of the combined character set forth above, in which the long unspun fibers are preferably coir fibers.

Still other objects of my invention will become evident from the following detailed description, taken in conjunction with the accompanying drawings:

Figure 1 of which is a view, partially in perspective and mainly in section with parts broken away, of a mattress or the like constructed in accordance with my present invention;

Figs. 2, 3 and 4 are fragmentary views showing on a magnified scale portions of vthe layers of material shown in Fig. 1;

Fig. 5 is a fragmentary view of a modified form of the invention; and

Figs. 6, 7 and 8 are views similar to Figs. 1, 2 and 3, respectively, of a modified form of my invention.

Referring to the drawings, I show therein a mattress I or the like, which may be provided with the usual series of individual coiled springs 2, braced or secured together in any familiar manner, which does not concern my present invention- On each side of the springs a pad 3 of felted long fibers, preferably coir fibers, is provided, being preferably backed on the face next to the spring ends by burlap or jute sheets 4, although these are not necessary in order to obtain the advantages of my present invention.

Top and bottom relatively thick layers 5 of cotton batts or felt made from short fibers of staple cotton or cotton linters are provided for affording the softness and depth required in a comfortable mattress or the like, and these outer layers 5 are maintained in position by reason of the interpostion of a relatively thin layer 6 of harsh fiber cotton felt or the like, which is disposed between the outer layer 5 of short fibers and the inner or base layer 3 of coir fibers.

The fibers Yof layer B are preferably of vegetable origin or their synthetic substitutes such as scrap rayon or Nylon fiber, which materials are materially cheaper and more readily availablethan long fibers of animal origin, such as horse, cow or pig hair.

The layers 3, preferably of coir fiber, may, as noted above, comprise other long unspun fibers, such as sisal, manila or palm fibers, although I have found that coir or cocoanut husk fibers are best suited for my purpose. The intermediate binding layers 6 are formed of some cotton felt characterized by the harshness of its fiber, such as certain imported staple cottons or bleached domestic linters, for example, or their synthetic substitutes. The harshness of such fibers permits the punching of their strands into the underlying coir fiber base, and this operation provides a relatively irregular or rough surface which causes the softer fibers of the ordinary cotton batts 5 to conform thereto and interlace with the intermediate felt layer to such an extent that the cotton batts or outer layers 5 do not shift or bunch with respect to the underlying layers.

Preferably the layers of long unspun fibers 3 and harsh cotton ber B are needled to a reinforcing burlap base 4 with layers 4 and 6 on opposite sides of layer 3, as explained in more detail in connection with Figs. 2, 3 and 4. After this needled pad has been prepared, however, there is no needling,.sewing or use of adhesives, as taught by the prior art, necessary in order to bond the outer layers of cotton batts 5 firmly in position.

The entire layer structure, as shown in Fig. l, is covered by a suitable upholstery cover or ticking 1 bound at the edges in accordance with familiar practice.

Referring to Figs. 2, 3 and 4, the layer 3 of coir fibers is shown as backed by a burlap layer 4 and topped by a thin layer 6 of the above-mentioned harsh fiber cotton. The depressions or indentations I0 on the outer surface of the layer 6 indicate the entry points of a needle or punch of a familiar type which carries some of the fibers from the layer 6 through the coir fiber layer 3 and into and beyond the backing layer 4 of burlapor the like, the fibers of the layer that intermingle with the coir fibers 3 being indicated by the reference character Il and the reference numeral l2 indicating the spots where cotton bers are forced by the punch or needle into or through the burlap backing.

However, if desired, in lieu of the use of such indentations for increasing the bonding or knitting action between the top and intermediate layers of the cotton felt, a certain indented pattern such as the lfamiliar waffle design shown in Fig. 5 may be employed, as will be understood.

If desired, the coir fiber base may be separately punched tothe burlap, and the harsh fiber cotton layer separately punched to the coir base, although preferably the three layers may be punched together in one operation, as descritlioed, assuming that the burlap is actually use In this way, a stable, readily handled pad comprising the three layers 6, 3 and 4 isprovided for placement on the coil spring assembly at one or both surfaces thereof, and the outer layers 5 of short fiber cotton or linter batts are then pressed onto the irregular outer surfaces of the layer 6 of harsh fiber cotton, the fibers at the junction planes matting or being pressed into intimate engagement to anchor the cotton batts in position without any other form of anchoring or retaining means being required, the surface irregularities of the thin layer 6 resulting from the punching operations being thus smoothed out to create an even and smooth unbroken surface for the application of the cover cloth.

In some instances, the use of a thick or relatively fluiiy outer layer of cotton batts may lend itself to undesirable body impressions, which will mar the appearance of a made-up bed.

To eliminate any such undesirable feature, in lieu of the relatively thin layer 6 of harsh fiber cotton felt or the like shown in Figs. 1, 2, 3 and 4, one or more layers I6 of such material are superimposed upon each other, and upon layer 6, as shown in Figs. 6, 7 and 8, being needled or punched to the coir fiber layer 3 or, if desired, the inner layer 6 being needled to the coir layer 3 and the outer layer to the inner layer, as the plural layer pad is built up. In practice, it has been found that one layer I 6, thicker than layer 6, both of harsh fiber cotton felt or the like, is fully satisfactory, being thus directly or indirectly needled or punched to the coir layer 3. The total preferred thickness of layers 6 and I6 is about 3A of the thickness of coir fiber layer 3.

The total thickness of the outer or top pad I5, of cotton batts or felt made from short fibers of staple cotton or cotton linters, may be made thinner than outer layer 5 of the mattress shown in Fig. 1, dependent upon the increased total thickness of the layers 6 and I6, to produce a mattress having the usual overall thickness. The intermediate pad constituted of the built-up layers 6 and I6 is matted to the outer layer I5, as in the case of layers 6 and 5 of Fig. 1.

By the use of the plural layers 6 and I6, a punched felt foundation is provided which has adequate compressive strength to yield under normal loads Without taking a permanent set, While the outer layers I5 are employed primarily to smooth out the punching indentations and thus obtain the desired smooth outer surfaces on the mattress.

The burlap reinforced construction of the pads is particularly desirable Where the surface of the supporting spring construction is rather open, that is, built up from coils with large top diameters, as shown. For spring assemblies manufactured from cloth pocketed coils, as in the familiar Marshall construction, or from a relatively large number of small diameter springs, assembled in an all steel construction by means of helical ties, the reinforcing backing may be conveniently omitted, the pad then being formed only from layers 3 and 6, punched together. I desire it to be understood, therefore, that the use of such burlap or jute backing is dictated by conditions which are not an essential part of the present invention.

In building up a mattress or other springcushioned article within the scope of my invention, a prefabricated'insulating pad of the character shown in Figs. 2, 3 and 4, or Figs. 6, '1 and 8, with or Without a Woven backing, is placed on one or more surfaces of the spring assembly, and suiiicient cotton or linter felt in the form of batts 5 added to provide the desired thickness. The entire set of layers, as illustrated in Fig. 1 or Fig. 6, is then attached to the spring assembly in a conventional manner by fastening around the edges, after which the indentations left from this operation are filled in with additional portions of felt to obtain a smooth surface. The assembly is then covered With the desired surface material or ticking I tailored to requirements.

'lightening or stretching of this outside cover or material during such tailoring process exerts adequate pressure on the cotton batts 5 to cause a natural intimate bond or matting between each of them and the adjacent layer of harsh fiber cotton needled to the coir fiber base. As a result, there is no tendency of the outer cotton batts 5 to shift with respect to the lower layers, and continued pressure on the mattress or other article caused by the use thereof will simply cause this natural bond to become firmer and firmer, thereby continually counteracting any tendency for the cotton batts to shift or ball up.

It will be seen that I have thus provided a comfortable, readily manufactured mattress or the like, having the desired smooth unbroken top and bottom surfaces, Without resort to tufting, sewing or even adhesives as means for securing the different layers of filling material in their relative positions to each other, the only needling or punching being employed underneath the entire depth of the outer cotton batts 5 as binder for the long unspun fibers of the base pad, such as coir, and a thin ply (or a series of layers) of harsh fiber cotton, with or Without a backing of burlap or the like for the coir fibers. `A

I do not Wish to be restricted to theI specific materials, structural details or arrangement of parts herein set forth, as various modifications thereof may be effected within the spirit and scope of my invention. I desire, therefore, that only such limitations shall be imposed thereon as are, indicated in the appended claims.

I claim as my invention:

l. An upholstery pad comprising a first layer of relatively long, harsh, unspun coir fibers', a second layer of relatively soft cotton fibers, and an intermediate thin layer of harsh cotton felt fibers the latter being interentangled with the fibers of said first layer at, at least, the surface thereof and matted to said second layer for frictionally bonding all three layers together into a coherent integral unit, all of said layers being garnetted.

2. An upholstery pad comprising outer layers respectively of garnetted coir-fiber felt and cotton-fiber felt, a plurality of thin built-up garnetted layers of fibers of a degree of harshness intermediate that of said outer layers, said builtup layers as a unit being disposed intermediate said outer layers and being needled to the coirfiber felt layer and matted with the layer of cotton-fiber felt for bonding all of said layers into a coherent unit.

3. An upholstery pad comprising outer layers respectively of garnetted coir-fiber felt and cotton-fiber felt, and an intermediate thin garnetted layer of felted cotton fibers of a degree of harshness intermediate that of said' outer layers, said intermediate layer being needled through the fibers of said coir-fiber felt layer and being matted to said cotton-fiber felt layer for frictionally bonding all three layers together into a coherent integral unit. Y

WALTER DE FRIES. 

